CN110007643B - Automatic on-line detection equipment and method for turnout manufacturing process - Google Patents
Automatic on-line detection equipment and method for turnout manufacturing process Download PDFInfo
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- CN110007643B CN110007643B CN201910421820.0A CN201910421820A CN110007643B CN 110007643 B CN110007643 B CN 110007643B CN 201910421820 A CN201910421820 A CN 201910421820A CN 110007643 B CN110007643 B CN 110007643B
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- 238000001514 detection method Methods 0.000 title claims abstract description 84
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 29
- 238000000034 method Methods 0.000 title claims abstract description 27
- 238000005259 measurement Methods 0.000 claims abstract description 109
- 238000012545 processing Methods 0.000 claims abstract description 63
- 238000003801 milling Methods 0.000 claims abstract description 34
- 238000010926 purge Methods 0.000 claims abstract description 16
- 238000013500 data storage Methods 0.000 claims description 21
- 238000003860 storage Methods 0.000 claims description 17
- 238000003754 machining Methods 0.000 claims description 12
- 238000007689 inspection Methods 0.000 claims description 8
- 239000000463 material Substances 0.000 claims description 3
- 238000012544 monitoring process Methods 0.000 claims description 3
- 238000010276 construction Methods 0.000 claims description 2
- 238000012886 linear function Methods 0.000 claims description 2
- 230000008569 process Effects 0.000 abstract description 16
- 238000004140 cleaning Methods 0.000 description 12
- 238000004458 analytical method Methods 0.000 description 10
- 238000010586 diagram Methods 0.000 description 6
- 230000005540 biological transmission Effects 0.000 description 5
- XEEYBQQBJWHFJM-UHFFFAOYSA-N Iron Chemical compound [Fe] XEEYBQQBJWHFJM-UHFFFAOYSA-N 0.000 description 4
- 230000000875 corresponding effect Effects 0.000 description 4
- 229910000831 Steel Inorganic materials 0.000 description 3
- 238000007664 blowing Methods 0.000 description 3
- 239000010959 steel Substances 0.000 description 3
- 238000010408 sweeping Methods 0.000 description 3
- 230000009466 transformation Effects 0.000 description 3
- 230000009286 beneficial effect Effects 0.000 description 2
- 238000004891 communication Methods 0.000 description 2
- 238000001914 filtration Methods 0.000 description 2
- 230000006872 improvement Effects 0.000 description 2
- 230000003993 interaction Effects 0.000 description 2
- 229910052742 iron Inorganic materials 0.000 description 2
- 238000005457 optimization Methods 0.000 description 2
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- 238000004364 calculation method Methods 0.000 description 1
- 230000008859 change Effects 0.000 description 1
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- 238000011161 development Methods 0.000 description 1
- 229910003460 diamond Inorganic materials 0.000 description 1
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- 238000009826 distribution Methods 0.000 description 1
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- 238000003384 imaging method Methods 0.000 description 1
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- 238000009434 installation Methods 0.000 description 1
- 230000001737 promoting effect Effects 0.000 description 1
- 230000009467 reduction Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
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Classifications
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- G—PHYSICS
- G01—MEASURING; TESTING
- G01B—MEASURING LENGTH, THICKNESS OR SIMILAR LINEAR DIMENSIONS; MEASURING ANGLES; MEASURING AREAS; MEASURING IRREGULARITIES OF SURFACES OR CONTOURS
- G01B11/00—Measuring arrangements characterised by the use of optical techniques
- G01B11/24—Measuring arrangements characterised by the use of optical techniques for measuring contours or curvatures
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/19—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by positioning or contouring control systems, e.g. to control position from one programmed point to another or to control movement along a programmed continuous path
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- G—PHYSICS
- G05—CONTROLLING; REGULATING
- G05B—CONTROL OR REGULATING SYSTEMS IN GENERAL; FUNCTIONAL ELEMENTS OF SUCH SYSTEMS; MONITORING OR TESTING ARRANGEMENTS FOR SUCH SYSTEMS OR ELEMENTS
- G05B19/00—Programme-control systems
- G05B19/02—Programme-control systems electric
- G05B19/18—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form
- G05B19/401—Numerical control [NC], i.e. automatically operating machines, in particular machine tools, e.g. in a manufacturing environment, so as to execute positioning, movement or co-ordinated operations by means of programme data in numerical form characterised by control arrangements for measuring, e.g. calibration and initialisation, measuring workpiece for machining purposes
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- Physics & Mathematics (AREA)
- General Physics & Mathematics (AREA)
- Human Computer Interaction (AREA)
- Manufacturing & Machinery (AREA)
- Automation & Control Theory (AREA)
- Length Measuring Devices By Optical Means (AREA)
- Machines For Laying And Maintaining Railways (AREA)
Abstract
The invention discloses an automatic on-line detection device and method for a turnout manufacturing process, wherein the detection device comprises the following components: a frame; the profile measuring module is arranged on the frame and is used for measuring the profile of the turnout rail piece to obtain profile measuring data; the distance measuring module is arranged opposite to the rack and is used for measuring the distance between the distance measuring module and the rack to obtain distance measuring data; the data receiving and storing module receives and stores profile measurement data and distance measurement data, and simultaneously retrieves and stores the turnout rail piece; the data processing module calls the profile measurement data and the distance measurement data and processes the profile measurement data and the distance measurement data to obtain three-dimensional profile data of the turnout rail piece, and calls the standard data of the turnout rail piece to compare with the three-dimensional profile data to form a detection report; and the purging module is arranged on the frame and used for purging the turnout rail piece. By the detection equipment, the automatic detection of geometric dimension of the numerical control milling contour is realized, and the measurement accuracy is improved.
Description
Technical Field
The invention belongs to the field of railway engineering equipment, and particularly relates to automatic on-line detection equipment and method for a turnout manufacturing process.
Background
Railway transportation is an important component part of economic development and infrastructure construction in China, and plays an extremely important role in promoting social progress in China and improving life quality of people; the turnout rail is a connecting and crossing structure of railway lines for allowing rolling stock to enter or cross another line, and is a key and weak link of railway transportation. The turnout has various types and complex structural forms, and the production and manufacturing precision directly influences the safety, the high efficiency and the comfort.
At present, the control and detection modes of the turnout rail part machining process mainly adopt manual detection, and the length position, the height, the rail head width and other single characteristics of the limited key section of the rail part are detected by using tools such as a tape measure, a caliper, a vernier caliper, a sample plate and the like, but the contour and the external processing surface of the key section cannot be detected; in addition, in the processing process of the turnout rail piece, the section size detection and the manual calculation of the feeding amount are required to be carried out every time of feeding, the time and the labor are wasted, the efficiency is low, and the detection result is easily influenced by subjective factors of detection environments and detection personnel.
Chinese patent CN106840033a relates to a rail profile parameter measuring device and method based on image processing. The rail profile detection device based on image processing is characterized by comprising four line laser sensors, a sensor bracket, a base, a rail conveying roller and a rail, wherein the non-contact laser imaging principle is utilized, four three-dimensional laser profile sensors are adopted to collect rail profile data, the image data collected by each sensor is subjected to coordinate transformation, rotation and translation, pattern splicing is carried out, the rail profile is obtained, and the calculated profile geometric dimension is compared with an iron mark for judgment. The invention provides a standard steel rail contour detection device and method, which have certain applicability, but cannot meet the detection of rail pieces with different rail types and different contours in the production process of a turnout rail piece under actual working conditions, cannot guide the process processing, and do not have informationized characteristics.
Disclosure of Invention
In order to solve the problems in the prior art, the invention provides automatic on-line detection equipment and method for a turnout manufacturing process. The technical problems to be solved by the invention are realized by the following technical scheme:
an automated on-line inspection apparatus for a switch manufacturing process, comprising:
a frame;
the profile measuring module is arranged on the frame and is used for measuring the profile of the turnout rail piece to obtain profile measuring data;
the distance measurement module is arranged opposite to the rack and is used for measuring the distance between the distance measurement module and the rack to obtain distance measurement data;
the data receiving and storing module is respectively connected with the profile measuring module and the distance measuring module and is used for receiving and storing the profile measuring data and the distance measuring data and simultaneously calling and storing the standard data of the turnout rail piece;
the data processing module is connected with the data receiving and storing module and is used for calling the profile measurement data and the distance measurement data and processing the profile measurement data to obtain three-dimensional profile data of the turnout rail piece, and calling the turnout rail piece standard data to compare with the three-dimensional profile data to form a detection report;
and the purging module is arranged on the frame and is used for purging the turnout rail piece.
In one embodiment of the present invention, further comprising:
the height adjusting unit is connected with the milling machine and used for adjusting the height of the frame;
the height measuring unit is connected with the height adjusting unit and is used for measuring the relative height of the rack;
the horizontal angle adjusting unit is connected with the height adjusting unit and the rack and is used for rotationally adjusting the horizontal position of the rack;
and the rotation adjusting unit is connected with the profile measuring module and the rack and is used for adjusting the scanning direction of the profile measuring module.
In one embodiment of the present invention, the profile measurement module may be any one of a laser line scan sensor, a binocular vision camera, or a laser radar.
In one embodiment of the invention, the data receiving and storing module comprises a data receiving unit and a data storing unit, wherein the data receiving unit is connected with the data storing unit, and meanwhile, the data receiving unit is respectively connected with the profile measuring module and the distance measuring module;
the data receiving unit is used for receiving the profile measurement data and the distance measurement data;
the data storage unit is used for storing the profile measurement data and the distance measurement data, and retrieving the standard data of the turnout rail piece for storage.
In one embodiment of the invention, the data processing unit comprises: a mobile terminal and a terminal;
the mobile terminal is used for displaying the profile measurement data and the distance measurement data in real time and monitoring the profile measurement data and the distance measurement data on line;
the terminal is used for obtaining the three-dimensional contour data according to the contour measurement data and the distance measurement data, calling the standard data and comparing the standard data with the three-dimensional contour data, and generating the detection report.
Another embodiment of the present invention further provides an automatic on-line detection method for a switch manufacturing process according to any one of the above embodiments, including:
placing the turnout rail piece on a milling machine for first machining;
measuring the turnout rail piece by using a profile measuring module and a distance measuring module to respectively obtain profile measuring data and distance measuring data;
the data receiving and storing module is used for receiving and storing the profile measurement data and the distance measurement data, and meanwhile, standard data of the turnout rail piece is called and stored;
processing the profile measurement data and the distance measurement data by using the data processing module to obtain three-dimensional profile data of the turnout rail piece after first processing, and simultaneously calling the standard data of the turnout rail piece to compare with the three-dimensional profile data, so as to calculate and obtain the cutter feeding amount of the turnout rail piece for second processing;
adjusting the processing track of the milling machine according to the cutter feeding amount, and then carrying out second processing on the turnout rail piece;
repeating the steps until the three-dimensional profile of the turnout rail piece meets the preset condition;
and processing the final profile measurement data and the distance measurement data of the processed turnout rail piece by using the data processing module, thereby obtaining a detection report.
The invention has the beneficial effects that:
1. the on-line detection equipment for the manufacturing process of the turnout rail piece has a simple structure and is convenient to use, the turnout rail piece is continuously detected through the laser line scanning sensor and the laser ranging sensor, so that the traditional product quality judgment can be finished, the data feedback of intermediate links can be carried out in the processing process, the processing guidance suggestion is provided for operators, and the problems that in a traditional manual detection system, the detection process is not automatic, human factors exist in detection errors, the turnout rail piece cannot be continuously detected and the like are solved;
2. according to the on-line detection equipment, the automatic detection of geometric dimensions of the digital milling contour is realized, the measurement accuracy is improved, the labor intensity of workers is reduced, the production efficiency is improved, the feeding amount of the turnout rail piece machining feed can be calculated and optimized based on the detected data, and the optimization and improvement of a forming cutter are guided, so that the product machining quality is ensured;
3. the invention can utilize the height adjusting module, the height measuring module, the horizontal angle adjusting module and the rotation adjusting module to adjust three deflection directions of the profile measuring instrument so as to adapt to the detection of turnout rail pieces of various rail type base lines with different rail gauges;
4. the automatic online detection equipment can interact with an enterprise information system to realize real-time transmission and storage of detection data so as to trace product information.
The present invention will be described in further detail with reference to the accompanying drawings and examples.
Drawings
FIG. 1 is a schematic diagram of an on-line inspection apparatus for use in the automated switch manufacturing process according to an embodiment of the present invention;
FIG. 2 is a schematic diagram of another embodiment of an automated on-line inspection apparatus for use in a switch manufacturing process;
FIG. 3 is a schematic diagram of an apparatus for on-line inspection of an automated switch manufacturing process according to an embodiment of the present invention;
FIG. 4 is a schematic view of the structure of the portion A in FIG. 3;
FIG. 5 is a schematic diagram of an operating state of a profile measurement module for an on-line inspection apparatus for use in a switch manufacturing process according to an embodiment of the present invention;
FIG. 6 (a) is a schematic diagram of an image structure of a standard rail member scanned by a profile measuring module for an automatic on-line detecting device for a switch manufacturing process according to an embodiment of the present invention;
FIG. 6 (b) is a schematic view of the image structure obtained by rotating the image in FIG. 6 (a);
FIG. 6 (c) is a schematic view of the image structure obtained after the image peaks in FIG. 6 (b) are overlapped;
FIG. 7 is a schematic diagram of an electrical connection for an automated on-line inspection apparatus for a switch manufacturing process according to an embodiment of the present invention;
fig. 8 is a schematic flow chart of an automatic on-line detection method for a switch manufacturing process according to an embodiment of the present invention.
Detailed Description
The present invention will be described in further detail with reference to specific examples, but embodiments of the present invention are not limited thereto.
Referring to fig. 1 to 4, an embodiment of the present invention provides an automatic on-line detection apparatus for a switch manufacturing process, the detection apparatus includes: a frame 2, a profile measuring module 3, a distance measuring module 4, a data receiving and storing module 1, a data processing module 5 and a purging module 7.
In one embodiment, the frame 2 is fixedly disposed on a beam of the milling machine 8, and is mainly connected to or disposed opposite to other measurement modules, so as to provide support for the whole online detection.
It should be noted that, the frame 2 may also be separately provided on a track and a power system, and not connected to the milling machine 8, and may specifically be provided according to actual requirements, and the embodiment of the present invention is not limited herein.
Further, the online detection apparatus is also provided with a height adjustment unit 21, a height measurement unit 22, a horizontal angle adjustment unit 23, a rotation adjustment unit 24; the height adjusting unit 21 is fixed on the milling machine 8 and is used for adjusting the height of the frame 2; a height measuring unit 22 is fixed to the height adjusting unit 21 for measuring the relative height of the frame 2, which is the height of the frame 2 relative to the milling machine 8; the frame 2 and the height adjusting unit 21 are connected through a horizontal angle adjusting unit 23, and the horizontal rotating position of the frame 2 can be adjusted through the horizontal angle adjusting unit 23; the rotation adjusting unit 24 connects the profile measuring module 3 with the frame 2 for fixing the profile measuring module 3 to the frame 2, and the rotation adjusting unit 24 can rotate the profile measuring module 3 to adjust the scanning direction thereof, wherein the profile measuring module 3 is a laser line scanning sensor 31.
Further, the height adjusting unit 21 is mainly composed of a lead screw guide 211 and a servo motor; the servo motor is controlled to drive the lead screw guide rail 211 to move, so that the frame 2 reaches a proper height; wherein, the model of the lead screw guide rail 211 is KR100; the servo motor is a 57S closed loop servo motor; the height measuring unit 22 is mainly composed of a short-distance laser ranging sensor 221, and the height of the frame 2 is measured by the short-distance laser ranging sensor 221, so that the relative height of the frame 2 is obtained; wherein, the model of the short-distance laser ranging sensor 221 is IL100; the horizontal angle adjusting unit 23 is mainly composed of a main rotation table 231, and the main rotation table 231 is manually rotated so that the frame 2 reaches a proper horizontal position; the rotation adjusting unit 24 is mainly composed of a sensor rotary table 241, and the scanning direction of the laser line scanning sensor 31 is adjusted by manually rotating the sensor rotary table 241, and the horizontal angle adjusting unit 23 and the rotation adjusting unit 24 may each employ a servo motor as a power device, and the embodiment of the present invention is not particularly limited herein.
Further, when the horizontal angle adjusting unit 23 and the rotation adjusting unit 24 each employ a servo motor as a power device, the height adjusting unit 21, the height measuring unit 22, the horizontal angle adjusting unit 23 and the rotation adjusting unit 24 are respectively connected with the data receiving and storing module 1, and are controlled by the data receiving and storing module 1 to perform various actions, so that the profile measuring module 3 is in a proper scanning position.
The adjustment of the frame 2 by the height adjustment unit 21, the height measurement unit 22, and the horizontal angle adjustment unit 23 is finally performed to bring the profile measurement module 3 to an appropriate scanning position.
Referring to fig. 5, it should be noted that the appropriate scanning position is a position that enables the profile measuring module 3 to completely scan the profile of the whole track, and simultaneously meets the height requirement, the width requirement and the section shape requirement of the switch track 6, and the switch track with different shapes has different requirements, and the position of the profile measuring module 3 can be set according to specific situations, which is not specifically described herein in the embodiments of the present invention.
Further, a profile measuring module 3 is disposed on the frame 2, and is configured to measure the profile of the switch rail member 6, so as to obtain profile measurement data.
Further, the profile measuring module 3 comprises a pair of non-contact laser devices which are oppositely arranged at two ends of the outer side wall of the frame 2 and are used for scanning the geometric profile of the turnout rail piece 6 and collecting data of profile points of the turnout rail piece 6; the non-contact laser device can be any one of a laser line scanning sensor, a binocular vision camera or a laser radar.
Preferably, the non-contact laser device is a laser line scanning sensor 31, and the model of the laser line scanning sensor 31 is LJV7300; the embodiment of the present invention uses the laser line scanning sensor 31 as an example, and describes the whole automatic on-line detection device.
Specifically, after the two laser line scanning sensors 31 are adjusted to appropriate scanning positions by the height adjusting unit 21, the height measuring unit 22, the horizontal angle adjusting unit 23 and the rotation adjusting unit 24, the turnout rail member 6 is scanned, the image data obtained by the two laser line scanning sensors 31 are subjected to rotation transformation according to a preset angle, and after the transformation is completed, the highest points of the two image data are overlapped, so that the two image data are completely spliced, and finally the complete outline of the turnout rail member 6 is formed.
Further, the preset angle is obtained by measuring the sampling of the calibration rail by the laser line scanning sensor 31 during the installation, specifically, please refer to fig. 6 (a) to 6 (c), the two scanned image data are rotated until the two image data are located in the horizontal direction, and the rotation angles are respectively denoted as θ 1 And theta 2 Namely, a preset angle; then findAnd (3) to the highest points P1 and P2 of the two image data, overlapping the P1 and the P2, so that the two image data are completely spliced to form the outline of the complete calibration track.
It should be noted that, the embodiment of the present invention only describes one way to splice two image data scanned by the laser line scanning sensor 31 to form a complete contour, and other reasonable ways may be adopted to splice the two image data, which is not limited herein.
Further, in order to avoid that the laser line scanning sensor 31 has an interference light source to interfere the scanning result when scanning the rail member, the two laser line scanning sensors 31 are respectively covered with a first light shield, and the first light shields are fixed at two sides of the frame 2 to wrap the laser line scanning sensor 31, so that only one surface which needs to emit laser is exposed.
Further, the distance measuring module 4 is disposed opposite to the rack 2, and is configured to measure a distance between the distance measuring module 4 and the rack 2, so as to obtain distance measurement data.
The opposite arrangement here means that the distance measuring module 4 can ensure that the emitted laser light impinges on the light reflecting plate 411 on the frame 2, so that accurate distance measurement data are measured.
Further, the distance measuring module 4 adopts a laser distance measuring sensor, and the laser distance measuring sensor emits laser to the frame 2 so as to obtain the distance between the distance measuring module 4 and the frame 2; the model of the laser ranging sensor is IL100; the distance measuring module 4 cooperates with the data of the profile points of the rail piece collected by the profile measuring module 3 to realize the three-dimensional data positioning of the turnout rail piece 6. The three-dimensional data of the switch rail member 6 specifically refers to two-dimensional data of a certain section of the switch rail member and position data of the section in the length direction of the switch rail member.
In a specific embodiment, in order to ensure the laser measurement accuracy of the laser ranging sensor when performing the distance measurement, an auxiliary device is further provided, and the auxiliary device comprises a second light shield and a reflecting plate 411, wherein the second light shield is covered on the whole milling machine 8 and is used for filtering an interference light source of the laser ranging sensor; the reflecting plate 411 is fixed on the frame 2 and is used for enhancing the detection light source of the laser ranging sensor, thereby ensuring the measurement accuracy of the laser ranging sensor.
Further, the reflector 411 is a diamond reflector.
Further, the data receiving and storing module 1 is respectively connected with the profile measuring module 3 and the distance measuring module 4, and is used for receiving and storing profile measuring data and distance measuring data, and calling and storing standard data of the turnout rail piece.
The standard data of the turnout rail piece refers to standard data of the geometric dimension of the end face of a preset turnout rail piece, and comprises standard values, tolerance, key section position information, linear functions among sections and rail piece information of the overall dimension of the preset turnout rail piece; the track piece information comprises information such as a drawing number, a construction number, materials and the like of a preset turnout track piece; the standard data of the turnout rail piece is used as a reference to assist the on-line detection equipment to work, so that the quality detection and judgment of the turnout rail piece 6 are completed.
Further, the data receiving and storing module 1 includes a data receiving unit 11 and a data storing unit 12, the data receiving unit 11 is connected with the data storing unit 12, and the data receiving unit 11 is connected with the profile measuring module 3 and the distance measuring module 4, respectively.
The data receiving unit 11 is configured to receive profile measurement data and distance measurement data; the data receiving unit 11 is mainly composed of an industrial control host and is responsible for controlling the profile measuring module 3, the distance measuring module 4 and running communication software, specifically, the data receiving unit 11 is connected with the profile measuring module 3 through gigabit Ethernet and adopts TCP/IP communication protocol; the device is connected with a distance measuring module 4 through a data transmission radio station and adopts a ModBus bus protocol; likewise, the transmission purpose may be achieved by adopting a limited manner and an equivalent protocol, and the embodiment of the present invention is not limited herein.
In addition, when the horizontal angle adjusting unit 23 and the rotation adjusting unit 24 use the servo motor as a power device, the data receiving unit 11 controls the height adjusting unit 21, the height measuring unit 22, the horizontal angle adjusting unit 23 and the rotation adjusting unit 24 to perform corresponding actions, so that the profile measuring module 3 is in a proper scanning position.
Further, the industrial control host can be any product capable of meeting the embodiment of the invention, such as a high-performance computer, a singlechip, a PLC, a motion control card and the like, and the type of the industrial control host can be TB-BPC.
The data storage unit 12 is used for storing profile measurement data and distance measurement data, when the automatic online detection device works, the milling machine 8 obtains different profile measurement data and distance measurement data after each feeding of the turnout rail piece 6, the profile measurement module 3 and the distance measurement module 4 acquire data of the turnout rail piece 6 once every 200Hz or higher, data are stored every 2mm as one point, the data are sent to the data storage unit 12 through the data receiving unit 11, the data in the data storage unit 12 are retrieved by the data processing module 5 and displayed in real time and detected online, the data detected by each feeding are stored in the data storage unit 12 until the turnout rail piece 6 is processed, all the measurement data are stored in the data storage unit 12, the data processing module 5 calls the data in the data storage unit and processes the data, so that a detection report is formed, and meanwhile, the data storage unit 12 calls the standard data of the turnout rail piece in advance from an enterprise information system; the data storage unit 12 is mainly composed of a storage server and is responsible for storing the data received by the data receiving unit 11, and the data storage unit 12 is based on an information system of an enterprise, and is mutually communicated with the information system of the enterprise through a 5.8GHZ wireless channel, so that product information interaction and association can be realized, and the detection parameters of the detection device are adjusted on line by calling the standard information of the turnout rail in the information system of the enterprise.
Further, the model of the storage server can be R230, the storage server uses an enterprise-level security disk, and a raid1 redundant array is established, so that data security is effectively ensured.
Further, the data processing module 5 is connected with the data receiving and storing module 1, and is used for calling and processing profile measurement data and distance measurement data to obtain three-dimensional profile data of the turnout rail piece 6, and calling and comparing the standard data of the turnout rail piece with the three-dimensional profile data to form a detection report for on-site processing guidance, product analysis and later tracing, so that man-machine interaction is realized.
Further, the data processing module 5 comprises a mobile terminal 51 and a terminal 52.
The mobile terminal 51 is used for displaying the profile measurement data and the distance measurement data in real time and monitoring on line; the mobile terminal 51 may be any mobile device meeting requirements, such as a tablet computer, a mobile phone, a PC, a dedicated server, etc., and the mobile terminal 51 is loaded with corresponding data processing software.
In addition, the mobile terminal 51 is in wireless connection with the data storage unit 12, so that information in the data storage unit 12 can be directly read and modified; the mobile terminal 51 sends the data collected on site to the data storage unit 12 for storage, so that the data can be conveniently checked later.
In a specific embodiment, the mobile end 51 may be further provided with a code scanning gun, and each switch rail member 6 is provided with a corresponding bar code, and the bar code corresponds to the standard data of the switch rail member; the bar codes on the turnout rail pieces 6 can be scanned by a code scanning gun, the obtained bar code data are sent to the data receiving unit 11, the data receiving unit 11 calls turnout rail piece standard data from an enterprise information system according to the requirements and stores the turnout rail piece standard data in the data storage unit 12, and the mobile terminal 51 calls related information from the data storage unit 12 and generates a site detection table, so that site machining is guided.
In one embodiment, mobile terminal 51 may also read data directly from the enterprise information system, and the mobile terminal 51 is connected to the enterprise information system through wireless communication.
The moving end 51 can process the data of the switch rail member 6 collected on site, display the width and the height of the specific section of the switch rail member 6 in real time according to the distance measurement data, form a three-dimensional profile shape, and compare the three-dimensional profile shape with the standard data of the switch rail member, so as to conduct on-site guidance on the processing of the switch rail member.
Here, the three-dimensional contour is a contour of a fixed cross-sectional position of the switch rail 6.
The terminal 52 is configured to obtain three-dimensional profile data of the switch rail member 6 according to the profile measurement data and the distance measurement data, and call preset switch rail member standard data to compare with the three-dimensional profile data, so as to generate a detection report for product analysis and later tracing; meanwhile, the detection report generated by the terminal 52 is simultaneously sent to the data storage unit 12 and the enterprise information system for storage.
After finishing processing the switch rail member 6, all real-time data are stored in the data storage unit 12, the terminal 52 calls the profile measurement data and the distance measurement data after the last processing from the data storage unit 12 to form complete three-dimensional profile data, builds a three-dimensional model, simultaneously calls the switch rail member standard data to compare with the three-dimensional profile data to generate a detection report, performs a numerical analysis, generates a dimension graph with a cross section as an abscissa and the width and the height of the switch rail member 6 as an ordinate, performs a line graph analysis, and analyzes and later traces the product according to the built three-dimensional model, the numerical analysis result and the line graph analysis result.
Further, the terminal 52 may be any mobile device satisfying requirements, such as a tablet computer, a mobile phone, a PC, and a dedicated server, and the terminal 52 is also loaded with corresponding data processing software.
Further, a purge module 7 is disposed on the frame 2 for performing a purge process on the switch rail member 6.
In a specific embodiment, the purging module 7 is an intelligent purging module, a machine vision system is adopted, a visual sensor is adopted to collect a view of the top of a turnout rail piece for a camera, and whether scrap iron influencing scanning exists on the top of the turnout rail piece 6 to be scanned is identified through the processes of binarization, filtering, XY axis gray scale change rate statistics and the like, then the pollution degree of the turnout rail piece 6 is automatically judged through a data receiving unit 11, and purging cleaning is carried out; the method for automatically judging the track pollution degree is visual detection, namely, the operation is performed through a machine vision system, and the mode of sweeping and cleaning is a combination of compressed air source sweeping and mechanical sweeping; wherein, the compressed air source purging adopts the equipment with air pressure of the milling machine 8.
It should be noted that, the machine vision system uses a machine to replace a human eye to make various measurements and judgments, the vision system refers to converting a captured object into an image signal through a machine vision product (namely an image capturing device, divided into a CMOS and a CCD), transmitting the image signal to a special image processing system, and converting the image signal into a digital signal according to information such as pixel distribution, brightness, color and the like; the image system performs various operations on these signals to extract the characteristics of the target, and further controls the operation of the on-site equipment, here referred to as the purge module 7, based on the result of the discrimination.
Further, referring to fig. 4 again, the intelligent purge module 7 in the embodiment of the present invention includes a camera 71, a connection frame 72, an air blowing device 73, and a mechanical cleaning device 74; the camera 71, the connecting frame 72, the air blowing device 73 and the mechanical cleaning device 74 are all arranged on the frame 2; the mechanical cleaning device 74 is fixed on the connecting frame 72 through a screw, and the mechanical cleaning device 74 drives the steel wire cleaning head through the cleaning RV speed reduction motor to fulfill the mechanical cleaning purpose; the mechanical cleaning device 74 may be a high-temperature resistant material cleaning head, a servo motor, or other equipment that satisfies the conditions.
The camera 71 captures an image of the switch rail 6, and transmits the image to an image processing system located on the data receiving unit 12, and then the image processing system performs discrimination and transmits the discrimination result to the data receiving unit 12, and the data receiving unit 12 controls the operation of the purge module 7 according to the discrimination result, and cleans the switch rail 6 by the air blowing device and the mechanical cleaning device.
Further, referring to fig. 7, 211 is a lead screw guide rail, which belongs to a main bearing component, is connected with the milling machine 8 through a steel adapter plate, and is fixed by screws; 25 is a lead screw adapter plate; 26 is a laser ranging sensor connection board; 221 is a short-range laser ranging sensor; 231 is a main rotation stage; 71 is a camera; 2 is a frame; 241 is a sensor rotation stage; 31 is a laser line scan sensor; 4 is a distance measurement module; wherein, the screw rod adapter plate 25 and the screw rod guide rail 211 are fixed along the direction of a broken line by screws; the main rotary table 231 is fixed on the bottom surface of the screw rod adapter plate 25 by screws; the laser ranging sensor connecting plate 26 is fixed on the vertical surface of the lead screw adapter plate 25 by screws; the short-distance laser ranging sensor 221 and the laser ranging sensor connecting plate 26 are fixed with screws; the camera 71 is fixed to the back surface of the sensor mounting plate 27 with screws; the sensor rotary table 241 is fixed to the upper surface of the sensor mounting plate 27 by screws; the laser line scanning sensor 31 and the sensor rotary table 241 are fixed by a single connector, and are fixed by screws to both sides of the connector.
After all the accessories are installed, in order to achieve the required measurement accuracy, some of the accessories need to be finely tuned, as shown by arrow direction in fig. 7, the main rotation table 231 can rotate in the horizontal direction to adjust the angle, so that the frame 2, the sensor rotation table 241 and the laser line scanning sensor 31 rotate along with them; in addition, the sensor rotary table 241 can be rotated in the vertical direction, as shown by the arrow direction in fig. 7, so that the measuring range of the laser line scanning sensor 31 can be adjusted to a precise position, thereby precisely measuring the profile of the switch rail 6 to be measured.
The automatic on-line detection equipment for the manufacturing process of the turnout rail piece has the working principle that:
the automatic on-line detection equipment for the manufacturing process of the turnout rail piece realizes the detection of the geometric dimension of the processing outline of the rail piece in a following mode, and the outline measurement module 3 acquires real-time outline data while feeding each time and realizes the positioning of three-dimensional data in combination with the distance measurement module 4; correspondingly, the profile measurement data and the distance measurement data are received and stored through the data receiving and storing module 1, and standard data are called from an enterprise information system to be stored; the data processing module 5 processes the profile measurement data, the distance measurement data and the standard data to form a data detection report for guiding processing, and associates the data detection report with the enterprise information system through wireless transmission, and stores the finally obtained detection data in the enterprise information system.
Further, referring to fig. 8, the embodiment of the invention further provides an automatic on-line detection method for the manufacturing process of the turnout, the detection method is implemented according to on-line detection equipment, and specifically comprises the following steps:
step (1): the switch rail member 6 to be measured is placed on a milling machine 8 for the first machining.
The automatic online detection equipment is arranged on a beam of the milling machine 8, wherein the distance measurement module 4 is arranged at one end of the milling machine 8 in the moving direction and is opposite to the reflecting plate 411 on the frame, and the milling cutter 9 is positioned on a main shaft at the front side of the beam of the milling machine 8, so that rail pieces are milled, and the turnout rail pieces 6 are fixed; according to the technological requirements, carrying out first machining on the turnout rail piece 6 to be machined; the feed rate of the first pass is determined by the particular process.
The front side here is based on the orientation or positional relationship described in the drawings.
Step (2): the profile measuring module 3 and the distance measuring module 4 are utilized to measure the turnout rail piece 6 after the first processing, and profile measuring data and distance measuring data are respectively obtained.
When the milling machine 8 finishes the first processing, the milling machine 8 needs to return to the initial position to perform the second processing, and in the process of returning the milling machine 8 to the initial position, the laser ranging sensor is used for recording the position information of the milling machine 8 every 2mm so as to obtain the position information of the turnout rail piece 6, and the laser line scanning sensor 31 is used for scanning the section of the processed turnout rail piece so as to obtain the section profile information of the turnout rail piece 6.
Since the detection device is mounted on the milling machine 8, the distance between the distance measuring module 4 and the frame 2, which is measured by the distance measuring module 4, is the distance between the distance measuring module 4 and the milling machine 8, the milling machine 8 and the switch rail member 6 move relatively, and the start position and the end position of the switch rail member 6 are detected and determined, so that the position information of any section of the switch rail member 6 can be determined.
Step (3): the profile measurement data and the distance measurement data are received and stored by the data receiving and storing module 1, and meanwhile, the standard data of the turnout rail piece are called from an enterprise information system and stored.
And the industrial control host is used for receiving the profile data of the different positions of the turnout rail piece and sending the profile data to the storage server for continuous storage.
The profile measurement data and the distance measurement data of the switch rail member 6 obtained by each feeding of the milling machine 8 are transmitted to the storage server to be stored.
Step (4): and processing the profile measurement data and the distance measurement data by using a data processing module 5 to obtain three-dimensional profile data of the turnout rail piece 6 after first machining, and simultaneously calling the standard data of the turnout rail piece to compare with the three-dimensional profile data, so as to calculate and obtain the cutter feeding amount of the turnout rail piece 6 for second machining.
The moving end 51 in the data processing module 5 calls the distance measurement data and the profile measurement data from the storage server, forms the three-dimensional profile shape of the turnout rail piece 6 in real time according to the distance measurement data and the profile measurement data, compares the three-dimensional profile shape with the turnout rail piece standard data, obtains information such as feed quantity, residual quantity, deviation quantity and the like generated in the processing process of the turnout rail piece 6, obtains the feed quantity of the cutter for the second processing, and displays the acquired data on the moving end 51 in real time so as to facilitate observation.
It should be noted that, the method for calculating the feeding amount of the cutter is an existing method, and the embodiments of the present invention are not described herein again.
Step (5): and adjusting the processing track of the milling machine 8 according to the cutter feeding amount, and then performing second-pass processing on the turnout rail piece.
And the profile measurement data obtained by the second processing and the distance measurement data are received by the industrial control host and stored in the storage server.
Step (6): repeating the steps (1) to (5) until the comparison of the three-dimensional profile and the profile standard data of the preset turnout rail piece 6 meets the preset condition.
Step (7): and processing the final profile measurement data and the distance measurement data of the processed turnout rail piece by using a data processing module, thereby obtaining a detection report.
After the turnout rail piece 6 to be processed is processed, in the process that the milling machine 8 returns to the initial position, the laser ranging sensor is utilized to record the position information of the milling machine 8 so as to obtain the position information of the turnout rail piece 6, the laser line scanning sensor 31 is utilized to scan the surface of the processed rail piece so as to obtain the section profile information of the turnout rail piece 6, the position information and the section profile information of the turnout rail piece 6 are sent to the data receiving and storing module 1 for storage, the data receiving and storing module 1 receives and stores the data and sends the data to the mobile terminal 51 for processing and displaying, then the terminal 52 calls the profile measurement data and the distance measurement data after the last processing from the data storing unit 12 to form a complete three-dimensional profile data, and establishes a three-dimensional model, meanwhile, the turnout rail piece standard data is called to be compared with the three-dimensional profile data to generate a detection report, a table analysis is performed, a turnout rail piece dimension chart with the section as a horizontal coordinate, the width and the height of the turnout rail piece 6 as a vertical coordinate is generated, and the product analysis and the later tracing result is performed according to the three-dimensional model, the analysis result and the table analysis result is performed; and after the detection is completed, the terminal 52 sends the finally obtained detection report to the data storage unit 12 for storage, and meanwhile, the data storage unit 12 uploads the detection report to the enterprise information system for storage backup.
The embodiment of the invention can achieve the following beneficial effects through the automatic detection equipment:
1. the on-line detection equipment for the manufacturing process of the turnout rail piece has a simple structure and is convenient to use, the turnout rail piece is continuously detected through the line laser vision sensor and the laser ranging system, so that the traditional product quality judgment can be finished, the data feedback of intermediate links can be carried out in the processing process, the processing guidance suggestion is provided for operators, and the problems that in the traditional manual detection system, the detection process is not automatic, human factors exist in detection errors, the turnout rail piece cannot be continuously detected and the like are solved;
2. according to the invention, through the online detection equipment, the automatic detection of geometric dimensions of the milling contour is realized, the measurement accuracy is improved, the labor intensity of workers is reduced, the production efficiency is improved, and the feeding amount of rail piece machining feed can be calculated and optimized based on the detected data, so that the optimization, improvement and product machining quality guarantee of a forming cutter are guided;
3. the invention can utilize the height adjusting module, the height measuring module, the horizontal angle adjusting module and the rotation adjusting module to adjust three deflection directions of the profile measuring instrument so as to adapt to the detection of turnout rail pieces of various rail type base lines with different rail gauges;
4. the automatic online detection equipment can interact with an enterprise information system to realize real-time transmission and storage of detection data so as to trace product information.
The foregoing is a further detailed description of the invention in connection with the preferred embodiments, and it is not intended that the invention be limited to the specific embodiments described. It will be apparent to those skilled in the art that several simple deductions or substitutions may be made without departing from the spirit of the invention, and these should be considered to be within the scope of the invention.
Claims (4)
1. An on-line detection device for automating a switch manufacturing process, comprising:
a frame;
the profile measuring module is arranged on the frame and is used for measuring the profile of the turnout rail piece to obtain profile measuring data; the profile measuring module comprises a pair of non-contact laser devices which are oppositely arranged at two ends of the outer side wall of the frame and used for scanning the geometric profile of the turnout rail piece and collecting the data of the profile points of the turnout rail piece; the non-contact laser device can be any one of a laser line scanning sensor, a binocular vision camera or a laser radar;
the distance measurement module is arranged opposite to the rack and is used for measuring the distance between the distance measurement module and the rack to obtain distance measurement data; the distance measuring module is arranged opposite to the rack, so that the distance measuring module can ensure that emitted laser just strikes a reflector on the rack, and accurate distance measuring data are measured;
the data receiving and storing module is respectively connected with the profile measuring module and the distance measuring module and is used for receiving and storing the profile measuring data and the distance measuring data and simultaneously calling and storing the standard data of the turnout rail piece; the standard data of the turnout rail piece refers to standard data of the geometric dimension of the end face of a preset turnout rail piece, and comprises standard values, tolerance, key section position information, linear functions among sections and rail piece information of the outline dimension of the preset turnout rail piece; the track piece information comprises a preset track number of a turnout track piece, a construction number and material information; the standard data of the turnout rail piece is used as a reference to assist the on-line detection equipment to work, so that the quality detection and judgment of the turnout rail piece are completed;
the data processing module is connected with the data receiving and storing module and is used for calling the profile measurement data and the distance measurement data and processing the profile measurement data to obtain three-dimensional profile data of the turnout rail piece, and calling the turnout rail piece standard data to compare with the three-dimensional profile data to form a detection report;
the purging module is arranged on the frame and is used for purging the turnout rail piece;
the online detection equipment is also provided with a height adjusting unit, a height measuring unit, a horizontal angle adjusting unit and a rotation adjusting unit; the height adjusting unit is fixed on the milling machine and used for adjusting the height of the frame; the height measuring unit is fixed on the height adjusting unit and is used for measuring the relative height of the frame, wherein the relative height is the height of the frame relative to the milling machine; the machine frame is connected with the height adjusting unit through the horizontal angle adjusting unit, and the horizontal position of the machine frame can be adjusted through the rotation of the horizontal angle adjusting unit; the rotary adjusting unit is connected with the profile measuring module and the frame and is used for fixing the profile measuring module on the frame, and the rotary adjusting unit can rotate the profile measuring module so as to adjust the scanning azimuth of the profile measuring module, wherein the profile measuring module is a laser line scanning sensor.
2. The on-line detection device for switch manufacturing process automation according to claim 1, wherein the data receiving and storing module comprises a data receiving unit and a data storing unit, the data receiving unit is connected with the data storing unit, and the data receiving unit is respectively connected with the profile measuring module and the distance measuring module;
the data receiving unit is used for receiving the profile measurement data and the distance measurement data;
the data storage unit is used for storing the profile measurement data and the distance measurement data, and retrieving the standard data of the turnout rail piece for storage.
3. The on-line inspection apparatus for use in connection with a switch manufacturing process of claim 1, wherein said data processing module comprises: a mobile terminal and a terminal;
the mobile terminal is used for displaying the profile measurement data and the distance measurement data in real time and monitoring the profile measurement data and the distance measurement data on line;
the terminal is used for obtaining the three-dimensional contour data according to the contour measurement data and the distance measurement data, calling the standard data and comparing the standard data with the three-dimensional contour data, and generating the detection report.
4. An automated on-line inspection method for a switch manufacturing process according to claim 1, comprising:
placing the turnout rail piece on a milling machine for first machining;
measuring the first processed turnout rail piece by using a profile measuring module and a distance measuring module to respectively obtain profile measuring data and distance measuring data;
the data receiving and storing module is used for receiving and storing the profile measurement data and the distance measurement data, and meanwhile, standard data of the turnout rail piece is called and stored;
processing the profile measurement data and the distance measurement data by using the data processing module to obtain three-dimensional profile data of the turnout rail piece after first processing, and simultaneously calling the standard data of the turnout rail piece to compare with the three-dimensional profile data, so as to calculate and obtain the cutter feeding amount of the turnout rail piece for second processing;
adjusting the processing track of the milling machine according to the cutter feeding amount, and then carrying out second processing on the turnout rail piece;
repeating the steps until the three-dimensional profile of the turnout rail piece meets the preset condition;
and processing the final profile measurement data and the distance measurement data of the processed turnout rail piece by using the data processing module, thereby obtaining a detection report.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN201811567596.8A CN109491322A (en) | 2018-12-21 | 2018-12-21 | One kind being used for switch manufacture process automation online detection instrument and method |
| CN2018115675968 | 2018-12-21 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CN110007643A CN110007643A (en) | 2019-07-12 |
| CN110007643B true CN110007643B (en) | 2024-01-02 |
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Family Applications (3)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201811567596.8A Withdrawn CN109491322A (en) | 2018-12-21 | 2018-12-21 | One kind being used for switch manufacture process automation online detection instrument and method |
| CN201920726708.3U Active CN210155545U (en) | 2018-12-21 | 2019-05-21 | Be used for automatic on-line measuring equipment of switch manufacturing process |
| CN201910421820.0A Active CN110007643B (en) | 2018-12-21 | 2019-05-21 | Automatic on-line detection equipment and method for turnout manufacturing process |
Family Applications Before (2)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN201811567596.8A Withdrawn CN109491322A (en) | 2018-12-21 | 2018-12-21 | One kind being used for switch manufacture process automation online detection instrument and method |
| CN201920726708.3U Active CN210155545U (en) | 2018-12-21 | 2019-05-21 | Be used for automatic on-line measuring equipment of switch manufacturing process |
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| Country | Link |
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| CN (3) | CN109491322A (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| CN109491322A (en) * | 2018-12-21 | 2019-03-19 | 中铁宝桥（南京）有限公司 | One kind being used for switch manufacture process automation online detection instrument and method |
| CN110143218B (en) * | 2019-06-27 | 2020-07-31 | 合肥工业大学 | Method and device for detecting straightness and torsion angle of high-speed railway turnout |
| CN112444198A (en) * | 2019-08-28 | 2021-03-05 | 中南大学 | Automatic detection and alarm system integrated equipment for geometric dimension of rail |
| CN110954028A (en) * | 2019-11-22 | 2020-04-03 | 四川深瑞视科技有限公司 | Track slab measuring system and track slab measuring method |
| CN110954027A (en) * | 2019-11-22 | 2020-04-03 | 四川深瑞视科技有限公司 | Track slab measuring system and track slab measuring method |
| CN111397535A (en) * | 2020-04-29 | 2020-07-10 | 苏州龙抬头智能科技有限公司 | Dynamic calibration method based on linear scanning laser and conveyor belt operating platform device |
| CN112147979B (en) * | 2020-09-22 | 2022-04-12 | 北京新风航天装备有限公司 | Machining online detection method based on three-dimensional model integrated application |
| CN112419394B (en) * | 2020-11-20 | 2024-04-30 | 中国铁道科学研究院集团有限公司 | Method and device for detecting turnout profile loss |
| CN112589534A (en) * | 2021-01-07 | 2021-04-02 | 中铁宝桥（南京）有限公司 | On-line detection equipment and detection method for numerical control drilling machining of turnout rail piece |
| CN112902867B (en) * | 2021-01-18 | 2023-06-02 | 北京京城智通机器人科技有限公司 | Track contour measuring method |
| CN113552845B (en) * | 2021-07-29 | 2022-06-21 | 重庆博张机电设备有限公司 | Measurement control method and flaker |
| CN114132358B (en) * | 2021-10-29 | 2023-03-14 | 北京自动化控制设备研究所 | Multi-platform intelligent track comprehensive detection system |
| CN114100876B (en) * | 2021-11-12 | 2024-07-23 | 深圳市奥极因科技有限公司 | Method for positioning and controlling deflection state of centrifuge rotor through intelligent algorithm |
| CN115493515A (en) * | 2022-09-05 | 2022-12-20 | 泰州市创新电子有限公司 | Binocular vision three-dimensional measurement method |
| CN115267407B (en) * | 2022-09-16 | 2023-01-03 | 北京中电飞华通信有限公司 | Equipment state early warning device based on artificial intelligence and early warning method thereof |
| CN115493477A (en) * | 2022-09-26 | 2022-12-20 | 中核武汉核电运行技术股份有限公司 | Automatic measuring method for cutting amount of heat transfer pipe orifice of steam generator |
| CN117048113B (en) * | 2023-10-13 | 2023-12-22 | 江苏爱箔乐铝箔制品有限公司 | Dynamic precision detection method and system for stamping aluminum foil cutlery box |
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Also Published As
| Publication number | Publication date |
|---|---|
| CN210155545U (en) | 2020-03-17 |
| CN109491322A (en) | 2019-03-19 |
| CN110007643A (en) | 2019-07-12 |
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